A123 Systems LLC

Duracell Inc.

Electrochem Solutions Inc.

Lithium Werks Technology Bv

William H Gardner

Lucien Paul Fontaine

Sean A Sargeant

Yet-Ming Chiang

Ricardo Fulop

John Hession

Karen E Thomas-Alyea

Charles E Martin

Douglas J Woodnorth

Keith M Bibby

Kevin Michael Li

Stefan Tillmann

Donald G Dafoe

Grace S Chang

Dale Beaver

Glen Dupliesea

Walter Carlson

Grace Sun Chang

Lucien Fontaine

Lithium ion (Li-ion) multi-cell batteries in which the requirements for individual monitoring and controlling charging of each cell, the requirements for monitoring and controlling charge balancing and the effects of repeated charging and discharging are ameliorated are presented. In one or more embodiments, the multi-cell battery includes configuration material that substantially provides a moisture barrier.

Multi-cell lithium-ion batteries

An insulation portion for an electrochemical cell having a plurality of slots into which bent electrode tabs are slid through during an assembly process of an electrochemical cell. A latch is disposed adjacent the slots and is movable from a resting position to a biased position to engage the electrode tabs. Attachment of the insulation portion to the electrochemical cell and bending of the electrode tabs can be robotically performed, such that controllers of an attachment device and bending device are in communication with each other.

Electrical insulator for electrochemical cell

An electrochemical cell includes components that are welded from an external source after the components are assembled in a cell canister. The cell canister houses electrode tabs and a core insert. An end cap insert is disposed opposite the core insert. An external weld source, such as a laser beam, is applied to the end cap insert, such that the end cap insert, the electrode tabs, and the core insert are electrically coupled by a weld which extends from the end cap insert to the core insert.

Method and design for externally applied laser welding of internal connections in a high power electrochemical cell

A battery management system includes one or more lithium ion cells in electrical connection, each said cell comprising: first and second working electrodes and one or more reference electrodes, each reference electrode electronically isolated from the working electrodes and having a separate tab or current collector exiting the cell and providing an additional terminal for electrical measurement; and a battery management system comprising a battery state-of-charge monitor, said monitor being operable for receiving information relating to the potential difference of the working electrodes and the potential of one or more of the working electrodes versus the reference electrode.

Lithium rechargeable cell with reference electrode for state of health monitoring

An electrochemical cell is provided. The cell includes a plurality of electrode sheets separated by at least one separator sheet. A positive extension tab is attached to a current collecting tabs of positive electrode sheets, and a negative extension tab is attached to current collecting tabs of the negative electrode sheets. The dimensions of the positive extension tab and the negative extension tab are selected such that temperature difference between positive extension tab and the negative extension tab are minimized when the electrochemical cell is in use.

Battery cell design with asymmetrical terminals

In some embodiments, a battery cell can include an assembly having an anode sheet and a cathode sheet separated by separator membranes, each sheet having an electroactive layer on a current collector. At least one of the current collectors can be in electrical communication with conducting tabs that extend from at least one of the anode sheet and the cathode sheet, the conducting tabs extends from an end face of the spirally wound assembly. In addition, the cell can include a first tab insulator having concentrically positioned outer and inner members, each of the outer and inner members having at least one slot that allows one or more of the plurality of conducting tabs to pass through. The inner and outer members are adjustable with respect to relative angular orientation of the at least one slot on the outer and inner members of the first tab insulator.

Battery cell design and methods of its construction

A cap assembly for use in an electrochemical cell. The cap assembly includes a tab collection post, a core insert, and at least one current collecting tab connected at one end to an electrode foil in the electrochemical cell, and horizontally connected at the other end to the tab collection post and the core insert. The at least one current collecting tab is disposed between and welded with the tab collection post and the core insert. The cap assembly also includes a shock absorber disposed around the core insert.

Cap assembly for a high current capacity energy delivery device

A protective housing for a circuit board mounted on an end of a cell is described. The protective housing includes a cut-out in its sidewall and a retaining wall centered in the cut-out. This provides a pair of gaps, one on each side of the retaining wall between the cut-out. These gaps are size so that lead wires extending from the circuit board are captured therein in a tight-fitting relationship. Consequently, the lengths of the leads extending from the protective housing of the cell to a quick disconnect at the distal end of the leads is precisely controlled. If desired, there can be more than one retaining wall providing a plurality of gaps for capturing a plurality of lead wires therein.

Electrochemical cell supporting a protective housing for electrical components

An end cap seal assembly for an electrochemical cell such as an alkaline cell is disclosed. The end cap assembly comprises a convoluted end cap disk which may also function as a cell terminal and an underlying insulating disk also having a convoluted surface. The convoluted end cap disk has a downwardly extending wall with at least one aperture therethrough which preferably faces the ambient environment. The insulating disk has a downwardly extending wall forming a rupturable membrane which underlies and abuts the inside surface of the downwardly extending wall of the end cap. The rupturable membrane underlies and abuts the aperture in the downwardly extending wall of the end cap. When gas pressure within the cell exceeds a predetermined level the rupturable membrane pushes through said aperture and ruptures allowing gas to escape therefrom directly to the environment. A separate terminal plate may be welded to a portion of the top surface of the convoluted end cap. The conductive layer of a film-laminate condition tester may be connected to the terminal plate.

End cap seal assembly for an electrochemical cell

The invention is directed to a method of forming a pip protrusion at the closed end of a cylindrical casing of an electrochemical cell. The cell is preferably an alkaline cell having an anode comprising zinc, a cathode comprising manganese dioxide, and an alkaline electrolyte. The method of the invention is directed to forming the pip protrusion at the closed end of the casing so that the pip protrusion becomes an integral part of the casing. In an alkaline cell the pip protrusion becomes the cell's positive terminal. The method of the invention involves inserting cathode material into the casing through the open end thereof and then forcing an elongated plunger having a diameter less than the inside diameter of casing into the cathode material while providing means for preventing the cathode material form rising more than a predetermined level with the casing. The force of the plunger causes the cathode material to become compacted while simultaneously causing a pip protrusion to form at the closed end of the casing.

Method of forming a terminal pip protrusion on the casing of an alkaline

An end cap assembly is disclosed for sealing the open end of a cylindrical alkaline cell housing preferably having a diameter less than the diameter of AAA size cells. The end cap assembly is preferably intended for sealing AAAA (LR61) size cylindrical alkaline cells. The end cap assembly comprises a terminal end cap, an insulating sealing disk underlying said end cap, and an elongated current collector penetrating through an aperture in said insulating sealing disk. At least a portion of the insulating sealing disk lies within the cell housing to seal the open end thereof. The terminal end cap has a peripheral edge, preferably formed from a curved rib, which is locked within the peripheral edge of the insulating sealing disk. The end cap assembly does not require other metal disks held within the sealing and insulating disk. The insulating disk comprises a discontinuous skirt comprising a plurality of integral legs emanating downwardly into the cell interior from the peripheral edge of said insulating disk. The insulating sealing disk has an integrally formed rupturable membrane therein. The membrane ruptures when gas pressure within the cell exceeds a predetermined level.

An end cap assembly is disclosed for sealing the open end of a cylindrical alkaline cell housing preferably having a diameter less than the diameter of AAA size cells. The end cap assembly is preferably intended for sealing AAAA (LR61) size cylindrical alkaline cells. The end cap assembly comprises a terminal end cap, an insulating sealing disk underlying said end cap, and an elongated current collector penetrating through an aperture in said insulating sealing disk. At least a portion of the insulating sealing disk lies within the cell housing to seal the open end thereof. The terminal end cap is located outside of said housing. The end cap assembly may include an insulating washer between the terminal end cap and the cell housing. The terminal end cap and the insulating washer are stacked over the peripheral edge of the cell housing at the open end of the cell housing. The insulating washer electrically insulates the terminal end cap from the cell housing. The insulating sealing disk has an integrally formed rupturable membrane therein. The membrane ruptures when gas pressure within the cell exceeds a predetermined level.

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East Freetown, MA, United States of America

William H Gardner